SOP Title: String Inverter Installation – Zeverlution ... · 1. Use the wall bracket as a drilling template and mark the positions of the drill holes. Ensure the bracket is levelled

STANDARD OPERATING PROCEDURE String Inverter Installation – Zeverlution Series

Version 1.2 Effective date 02/08/2017

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SOP Title: String Inverter Installation – Zeverlution Series

Version: SOP1103-PV-v1.2 Effective Date: 02/08/2017

DOCUMENT CONTROL

Version no. Date Significant Changes Author Reviewer

1.0 08/05/17 Draft Timm Brehm TH, AF, ME, KW

1.1 03/07/17 Issued Timm Brehm TH, AF, ME, KW

1.2 02/08/17 Monitoring setup revised T Heine TB

Table of Contents

PURPOSE ..................................................................................................................................... 2

SCOPE .......................................................................................................................................... 2

SYMBOLS USED IN THIS DOCUMENT ............................................................................................ 2

GENERAL GUIDELINES .................................................................................................................. 2 BEHAVIOURAL .................................................................................................................................. 2 SAFETY ............................................................................................................................................. 2

INSTALLATION PROCEDURE ......................................................................................................... 3 String Design Guidelines ................................................................................................................... 3

5.1.1 String Layout Without Optimisers ....................................................................................................... 3 5.1.2 String Layout with Optimisers .............................................................................................................. 3 5.1.3 Shading ................................................................................................................................................. 3 5.1.4 Maximum String Voltage...................................................................................................................... 4 String Inverter Installation ................................................................................................................ 4

5.2.1 Zeversolar Zeverlution 2000s ............................................................................................................... 4 5.2.2 Zeversolar Zeverlution 4000 ................................................................................................................ 4 5.2.3 Wall Mounting ..................................................................................................................................... 5 Wiring .............................................................................................................................................. 6

5.3.1 DC Wiring ............................................................................................................................................. 6 5.3.2 TS4-R-O Optimiser installation ............................................................................................................. 9 5.3.3 AC Wiring ........................................................................................................................................... 10

SYSTEM COMMISSIONING ......................................................................................................... 11 Commissioning Tests ...................................................................................................................... 11 Grid Protection Settings ................................................................................................................. 11

6.2.1 Adjusting grid protection settings using the inverter display ............................................................ 11 Connecting the inverter to the Internet ........................................................................................... 12

6.3.1 Connecting the inverter to the internet using WIFI ........................................................................... 13 6.3.2 Connecting the inverter to the internet using Ethernet .................................................................... 15



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PURPOSE This document provides all solarcity installation partners and employees with guidelines and instructions for the installation of single and dual MPPT inverters for residential solarZero and solarClassic systems.

SCOPE This document applies to single-phase installations with Zeversolar string inverters and covers the mechanical and electrical part of the inverter installation instruction. The focus of this SOP lies on the physical installation of Zeverlution 2000s and Zeverlution 4000 inverters and any associated switch gear, DC and AC wiring.

SYMBOLS USED IN THIS DOCUMENT

Danger: destruction of property, serious injury or death may occur

Warning: Damage to equipment/ property or minor injury may occur

Note: for informational purposes

Reference to other section in this document, or an external document.

GENERAL GUIDELINES

BEHAVIOURAL

Always follow solarcity’s Code of Conduct while on site.

SAFETY

Follow NZ Health & Safety laws and regulations, your company’s and/or solarcity’s Health & Safety Policy.



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INSTALLATION PROCEDURE

String Design Guidelines

To ensure efficient operation and compliance with the regulations, string design options are limited. As per AS/NZS 5033 section 2.1.6, PV modules that are in the same string must have the same tilt and azimuth angle within a tolerance of ±5°.

solarcity will determine which layout is most suitable based on a site visit prior to the installation. If you find the provided layout to be unsuitable on the day of installation, please contact solarcity immediately. The below section should provide a better understanding of our design guidelines. As a solarcity installer or contractor, you are expected to report any possible discrepancies with the below design guidelines immediately before you proceed with your work.

For both the Zeverlution 2000s and the Zeverlution 4000 inverters and for arrays with or without optimisers the minimum and maximum strings lengths are as follows:

- minimum number of modules per string is 3

- maximum number of modules per string is 10

5.1.1 String Layout Without Optimisers Where no optimisers are deployed, modules that are electrically connected as one string need to be in the same orientation and tilt.

5.1.2 String Layout with Optimisers The deployment of Tigo TS4-R-O optimisers allows modules in a single string to be installed as split-arrays with different azimuth and/or tilt angles. As a general guideline, the main or most north facing array must have a minimum of 3 modules to reach the inverters start up voltage and won’t be optimized – while the “sub-array” will be optimized. Examples of array configurations and the correct deployment of optimisers are shown below (with optimized modules shown in blue).

5.1.3 Shading

The benefit of optimisers in partially shaded arrays is insignificant. For solarZero systems, in some instances, shading is mitigated by installing one additional module. solarcity will determine if this is a suitable solution on a case by case basis.



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5.1.4 Maximum String Voltage The maximum length of a single string is dictated by the string voltage, taking temperature coefficients and the local ambient temperatures into account. For all solarcity installation zones, the maximum number of panels in a single string of 60-cell modules with a rated output at STC of less than or equal to 300 Watts, is ten (10). The string length is also limited by the DC isolator’s rating.

String Inverter Installation The following section describes the physical installation of the string inverter for solarZero and solarClassic systems. The range of string inverters is currently limited to two models, a 2kW and a 4kW unit.

5.2.1 Zeversolar Zeverlution 2000s This inverter is used for systems with a peak output between 1.5kWp and 3kWp (6 to 10 modules), where the peak performance rating per panel at STC does not exceed 295Wp.

For further details please refer to the Zeverlution 2000s datasheet.

DC Input

The inverter is equipped with a single MPPT input. The single string is connected using SUNCLIX connectors of which one pair is supplied with the inverter.

Model Zeverlution 2000s

Convertible power 2350W

Max input voltage 500V

MPP voltage range 70V - 450V

Min DC start voltage 80V

Max DC input current 11A

AC Output

The inverter has an AC screw terminal block for connecting the AC cabling.

Model Zeverlution 2000s

Rated active power 2000W

Max apparent power 2200VA

Rated grid voltage 230V

Max AC output current 10A

Min MCB rating 16A (type C)

5.2.2 Zeversolar Zeverlution 4000 The Zeverlution 4000 inverter is used for systems with a peak output between 3.4kWp and 6kWp.

For further details please refer to the Zeverlution 4000 datasheet.

DC Input

The inverter has 2 individual MPPT inputs and comes with 2 pairs of SUNCLIX connectors.

http://www.solarcity.co.nz/assets/Uploads/productmanuals/zeversolar-datasheet-single-phase-inverters-zeverlution-s-en.pdf

http://www.solarcity.co.nz/assets/Uploads/productmanuals/zeversolar-datasheet-single-phase-inverters-zeverlution-3680-4000-5000-en.pdf



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Model Zeverlution 4000

Convertible power 4650W

Max input voltage 600V

MPP voltage range 100V - 520V

Min DC start voltage 80V

Max DC input current 11A / 11A

AC Output

The inverter has an AC screw terminal block for connecting the AC cabling.

Model Zeverlution 4000 Rated active power 4000W

Max apparent power 4400VA

Rated grid voltage 230V

Max AC output current 20A

Min MCB rating 25A (type C)

5.2.3 Wall Mounting Mounting procedure

The inverters come with a mounting bracket, which is used to fix the units to a suitable wall.

Please refer to the solarcity wall cladding guide for suitable wall claddings to mount the inverter on.

1. Use the wall bracket as a drilling template and mark the positions of the drill holes. Ensure the bracket is levelled before drilling. If the supplied anchors and screws are used, drill 2 holes with a diameter of 10mm to a depth of 70mm. Place the anchors in the wall and secure the bracket with the supplied hex-head screws.

2. Once the bracket is securely mounted to the wall, attach the inverter onto the bracket. Check both sides of the heatsink to ensure the inverter is positioned correctly.

3. Push the inverter towards the wall as far as possible and secure it on both sides of the wall bracket using the provided M5 screws (torque 2.2 Nm).



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Clearances

Heat must be able to dissipate from the inverter through the heatsink on the back. It is important to consider the recommended clearances. The below table is for a single inverter only.

Multiple inverters should only be installed side by side horizontally and never vertically stacked one above the other.

Suitable locations

Suitable locations are the south, southeast and southwest facing walls of a building or the garage. Porches that offer sufficient shelter can also be suitable. The inverter must not be installed in a location, where it is exposed to direct sunlight.

Wiring

5.3.1 DC Wiring

All wiring must be installed and sized in accordance with the relevant requirements of AS/NZS 3000, AS/NZS 3008.1, AS/NZS 5033 and AS/NZS 4777.1.

All DC cabling and the associated earth bonding conductors should be bundled together to avoid induction loops. Where possible, use the so-called “leapfrog wiring” method to avoid unnecessary cable loops and home runs.

Source: http://solarprofessional.com/sites/default/files/articles/images/1_SP7_3_pg12_QA_1-1.jpg

If the leapfrog or skip wiring method is impractical, the modules can be daisy chained.

Source: http://solarprofessional.com/sites/default/files/articles/images/1_SP7_3_pg12_QA_1-1.jpg

Direction Minimum Clearance

above 300 mmbelow 500 mmsides 400 mm

http://solarprofessional.com/sites/default/files/articles/images/1_SP7_3_pg12_QA_1-1.jpg

http://solarprofessional.com/sites/default/files/articles/images/1_SP7_3_pg12_QA_1-1.jpg



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Any DC cabling must be adequately mechanically protected and must be run in HD Solar conduit. Where it is exposed to direct sunlight, HD conduit, marked with the letter T, is to be used. For any internal cable runs (e.g. within wall cavities, under floors and within roof spaces), rigid HD solar conduit shall be used. The conduit must be labelled with PV or SOLAR at intervals not exceeding 2 meters. Refer to section 4.3 of AS/NZS 4777.1:2016. Use stainless steel saddles for all external conduit runs.

Wiring between the inverter and the DC isolator may be without conduit where the length of DC cable does not exceed 300mm.

The minimum cross section of any DC wiring is 4mm². All DC cables shall be multi-stranded, insulated and sheathed and PV1-F rated as per AS5033. The table below shows the maximum cable length (one way) between array and inverter with JA 290W panels, allowing for a 2% voltage drop.

Panels per string 3 4 5 6 7 8 9 10

Max. cable length 25 25 25 30 35 40 45 50

Genuine MC4 connectors must be used to connect the DC cables to the array output cable. A MC4 crimping tool is required to attach the stranded wire to the metal pin.

DC isolators

DC isolators must be installed adjacent to the inverter. The clearances for the inverter provided in section 5.2.4 do not apply for any disconnection equipment. This means isolators can be installed directly underneath or next to the inverter.

Solarcity supplies a Kraus & Naimer DC isolator - KFD25 T204/NZ-P002 KL11V. It is important that the screw terminals of the DC isolator are not over tightened. A torque screwdriver shall be used to tighten the terminal screws with a torque of 1.25Nm.

Remove the isolator from the enclosure prior to fixing the enclosure to the wall. Dust from drilling can damage the switch.

Please see the isolator datasheet for further details.

http://www.solarcity.co.nz/assets/Uploads/productmanuals/KFD25-T204-NZ-P002-KL11V-GB1.pdf



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SUNCLIX Connectors

The inverter uses SMA’s SUNCLIX to connect the DC string to the inverter. One (Zeverlution 2000s), or two pairs (Zeverlution 4000) respectively, are shipped with the inverter. It is important to assemble the connectors correctly. Please take extra care not to damage these connectors in the process. Be sure to maintain the correct polarity – the connectors are also marked with “+” and “-“ symbols.

The steps below explain how to assemble SUNCLIX connectors. Ensure that the array cable is de-energized before installing the connectors.

1. Strip approx. 12mm off the cable insulation

2. Route the cable all the way into the DC connector. Ensure that the stripped cable and the DC connector have the same polarity

3. If the stranded wires are visible in the chamber of the clamping bracket, the cable is positioned correctly. Press the clamping bracket down until it snaps into place. You should hear a click.

4. Push the swivel nut up to the thread and tighten it (torque: 2Nm).



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5. If the connector’s clamping bracket was locked prematurely (refer to step 3), it can be opened using a 3.5mm flat bladed screw driver

Equipotential Bonding

Equipotential bonding is required for all parts of the solar array. The cross section of each earth conductor should be equal or greater than that of the DC cable conductor size. The earth cable must be continuous from the array to the earth bar in the switchboard the inverter is connected to. Run all conductors bundled in the same conduit.

solarcity policy is that the earth conductor must be bonded to every rail in each row or column of the array using the supplied proprietary earth lugs.

Roof Penetration

Subject to the roof type the PV array is installed on, an appropriate roof penetration kit must be used. Roof penetrations must always be located under the solar panels where an attic space is accessible for the cable run.

Where cable(s) pass through the roof penetration, it must be protected using rigid conduit.

Rooftop Isolator

A rooftop isolator is not required. Refer to section 4.4.1.6 of AS/NZS 5033:2014 for details. The output cabling of the array must be labelled as follows:

“The inverter DC isolator must be in ‘Off’ position before isolating the PV array”

5.3.2 TS4-R-O Optimiser installation

Where strings are split across two roofs with different orientations or roofs with different pitch, optimisers must be partially deployed in the string (see 5.1.2). solarcity will specify the design and optimiser deployment prior to the installation. Follow the below instructions to retrofit optimisers to the module.

1. Looking at the back of the panel, push the optimisers into the upper right corner at the backside of the module frame as depicted. Make sure the unit is pushed all the way in.



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2. Connect the module leads to the short input leads of the TS4-R-O unit.

3. Connected the long output leads of the optimiser to the output leads of the next optimiser.

Secure any wiring loops and loose cables to the module frame or the mounting rails. All optimisers come with genuine MC4s and so do the modules. If you find non-genuine connectors on either the module or the optimisers, please contact solarcity immediately. The optimiser’s output leads have a length of 1000mm which is usually too short for leapfrog wiring. Please use standard daisy chain wiring for all optimised array sections.

5.3.3 AC Wiring

The inverter is connected to the switchboard using double insulated 3-core cable (2C+E). Circular TPS should be used to connect the inverter to the AC isolator. Standard TPS cable can be used for the cable run between switchboard and AC isolator. If no AC isolator is required, use circular TPS all the way from the inverter to the switchboard. External AC cabling must be run in UV resistant HD conduit (with the Solar T labelling hidden since it is AC not DC).

The table below shows the conductor cross section and maximum cable length for each inverter.

2.5mm² 4mm² 6mm²

Zeverlution 2000s 15m 25m 40m

Zeverlution 4000 n/a 15m 20m

max. cable length conductor cross-section



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An AC isolator must be installed adjacent to the inverter if the inverter is more than 3 meters away from the switchboard or it is out of line of sight. The AC isolator must have a current rating equal to or greater than the MCB current rating.

MCB’s must be sized correctly according to the cable cross section used to connect the inverter to the switch board. Please refer to the inverter datasheet or sections 5.2.1 and 5.2.2 to determine the appropriate MCB rating.

SYSTEM COMMISSIONING

Commissioning Tests

It is extremely important that all mandatory tests are done before commissioning the PV system. Please make yourself familiar with Appendix D of AS/NZS 5033:2014 and follow the instructions outlined in the standard.

Attached to this document you’ll find a commissioning sheet which you may use to record the test results. A completed and signed copy of the commissioning sheet together with the CCSC must be provided to solarcity.

Grid Protection Settings AS4777.2:2015 defines specific grid protection requirements for New Zealand. Before commissioning the PV system, you must ensure that the inverter is set to the correct standard.

6.2.1 Adjusting grid protection settings using the inverter display

To change these settings, the inverter must be powered by DC only.

Keep in mind that the inverters need a minimum DC input power of 30Watts from the array to start up. If the irradiance is insufficient in the late evening, you might not be able to access the inverters settings menu.

1. With the AC isolator turned off, turn on the DC isolator(s) and wait for the inverter to start. This may take a few seconds. The display will show an error code.



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2. Once the inverter has started, use the grey button next to the display to change the information shown on the display until the inverter name is displayed, e.g. Zeverlution 4000 or Zeverlution 2000s.

3. When the inverter name is displayed, push and

hold down the button for 10 seconds. You will be asked to enter a password.

4. The password is 25. The 3-digit number will

count-up by one each time you press the button. Push the button repeatedly until the number 024 is displayed. Now push the button one more time but hold it down for 10 seconds. The inverter is most likely set to Australian settings by default.

5. Now press the button again once per second until

the display shows the correct standard -NZ AS/NZS4777.2. To confirm, wait for approximately 10 seconds until the inverter automatically returns to the initial display, showing the error code.

Connecting the inverter to the Internet The inverter needs to be connected to the customer’s internet connection so that it can be monitored for performance and maintenance (e.g. earth faults). This can be done via WIFI or Ethernet. The order of preference for internet connection is as follows:

1. If there is WIFI signal at the inverter location, connect via WIFI – refer to section 6.3.1 for connecting the inverter using WIFI

2. If there is no WIFI signal at the inverter location, use a TPLink WIFI extender to extend the WIFI signal to the inverter location – refer to section 6.3.1 for connecting the inverter using WIFI

3. If WIFI cannot be extended to the inverter location, use an Ethernet bridge to connect the inverter directly to the customer’s router. This example may arise if the inverter is installed in a garage away from the main house. Where the cable run is relatively short, it is preferable to run an



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Ethernet cable directly to the router. Refer to Section 6.3.2 for connecting the inverter using Ethernet.

6.3.1 Connecting the inverter to the internet using WIFI

1. Install the supplied WIFI antenna to the bottom of the inverter before setting up the WIFI connection.

2. With the inverter powered up, use a smartphone or laptop to search for the inverter’s wireless access point. This will display as ZEVERSOLAR-XXXX. Connect to this using the password ‘zeversolar’.

3. Open a new browser window and

enter http://160.190.0.1 in the address bar to access the inverter settings interface.

4. If the address cannot be loaded, press

the button on the inverter display to cycle through the menu until an IP address is displayed. If this isn’t 160.190.0.1 use the IP address shown on the inverter’s display .

http://160.190.0.1/



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5. Select the wireless menu and connect to the customer’s wireless network.

6. After approximately one minute the

inverter should connect to the customers wifi network and the status indicator on the wireless page will show a green tick.

7. Take a photo of the serial number and

reg. key of the inverter. The label is usually placed on the right side of the inverter. Upload this photo to google drive as part of the installation photos.



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6.3.2 Connecting the inverter to the internet using Ethernet To use this method the customers router must have DHCP enabled.

1. Connect the Ethernet port on the inverter to the Ethernet port on the customers router directly via and Ethernet cable or Ethernet bridge. The Ethernet port in the inverter is labelled ‘ETH’.

2. Run the Ethernet cable through the comms gland on the bottom of the inverter ensuring that the cable entry is sealed from dust and moisture.

3. The inverter automatically obtains an IP address from the router via DHCP and connects to the internet. This process may take a minute or two.

4. Press the button on the inverter display to cycle through the menu until an IP address is displayed. If the inverter is connected to the internet ‘Connected’ should show beneath the IP address.

5. Take a photo of the serial number and reg. key of the inverter. The label is usually placed on the right side of the inverter. Upload this photo to google drive as part of the installation photos.

Commissioning Test Sheet Residential - String Inverter

CTS1039-PV-v4 Page 1 of 1

solarcity PV array commissioning sheet

Address of installation

COC Reference/Certificate ID Number

Date of Testing

Number of PV modules in string 1

Number of PV modules in string 2 (if applicable)

Number of DC optimisers (if used)

Continuity

Earth continuity 1 – Earth busbar to earth rod (MEN link removed) Ω

Earth continuity 2 – Main earth conductor to array frame Ω

Polarity check and PV open circuit voltage

Polarity Voltage (V)

String 1

String 2 (if applicable)

PV array at switch disconnector

Insulation resistance measurements Array positive to earth MΩ

Array negative to earth MΩ

System Operation

PV operating voltage V

PV operating current – string 1 A

PV operating current – string 2 (if applicable) A

PV array switch-disconnector operating correctly under load YES / NO

Time of day

Sunlight/irradiance at time of testing SUNNY / CLOUDY – BRIGHT / CLOUDY - DARK

Documents

SOP Title: String Inverter Installation – Zeverlution ... · 1. Use the wall bracket as a drilling template and mark the positions of the drill holes. Ensure the bracket is levelled